Adjustable shoe for a power tool

ABSTRACT

A band saw includes a first wheel and a second wheel for supporting a continuous band saw blade, a motor operable to drive at least one of the first and second wheels, a housing supporting the first wheel and the second wheel, a shoe for engaging a workpiece, the shoe including a first detent feature. The band saw also includes a second detent feature cooperating with the first detent feature to hold the shoe with respect to the housing. The shoe is moveable with respect to the housing between an engaged position and a non-engaged position. The shoe is moveable out of the engaged position by application of a force acting to move the shoe with respect to the housing sufficient to overcome cooperation between the first and second detent features in the engaged position.

RELATED APPLICATIONS

This application is a continuation of co-pending U.S. patent applicationSer. No. 12/508,824 filed on Jul. 24, 2009 which claims priority to U.S.Provisional Patent Application Ser. No. 61/083,703 filed on Jul. 25,2008, and this application is also a continuation of co-pending U.S.patent application Ser. No. 12/794,023 filed on Jun. 4, 2010 which is acontinuation-in-part of U.S. patent application Ser. No. 12/508,824filed on Jul. 24, 2009 which claims priority to U.S. Provisional PatentApplication Ser. No. 61/083,703 filed on Jul. 25, 2008, the entirecontents of all of which are incorporated herein by reference.

BACKGROUND

The present invention relates to workpiece locators for power tools, andmore particularly for band saws.

A band saw typically includes a drive wheel pulley, a motor coupled tothe drive wheel pulley to drive the drive wheel pulley, a driven wheelpulley, and a continuous band saw blade looped around the drive wheeland the driven wheel. Band saws may also include a shoe to locate aworkpiece with respect to a cutting portion of the band saw blade. Theworkpiece may be large or small and take on many various shapes. Toremove the shoe or adjust a position of the shoe depending on theworkpiece or type of cut to be made, a user uses a tool to release theshoe from a first position and secure it in a second position.

SUMMARY

In one aspect, the invention provides a band saw. The band saw includesa first wheel and a second wheel for supporting a continuous band sawblade, a motor operable to drive at least one of the first and secondwheels, and a housing supporting the first wheel and the second wheel.The band saw also includes a shoe for engaging a workpiece, the shoeincluding a first detent feature. The band saw also includes a seconddetent feature cooperating with the first detent feature to hold theshoe with respect to the housing. The shoe is moveable with respect tothe housing between an engaged position in which the first and seconddetent features cooperate to hold the shoe with respect to the housing,and a non-engaged position in which the first and second detent featuresdo not cooperate. The shoe is moveable out of the engaged position byapplication of a force acting to move the shoe with respect to thehousing sufficient to overcome cooperation between the first and seconddetent features in the engaged position.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side perspective view of a band saw including an adjustableshoe system according to one embodiment of the invention.

FIG. 2A is a bottom perspective view of the band saw of FIG. 1.

FIG. 2B is a top perspective view of a portion of the band saw shown inFIG. 1.

FIG. 3 is an exploded perspective view of the adjustable shoe system ofFIG. 1.

FIG. 4 is a perspective view of the adjustable shoe system of FIG. 1.

FIG. 5A is a cross section of the adjustable shoe system taken alongline 5A-5A of FIG. 4.

FIG. 5B is a cross section of a portion of the band saw taken along line5B-5B of FIG. 2B.

FIG. 6 is a rear perspective view of the adjustable shoe system of FIG.1.

FIG. 7 is a cross section of the adjustable shoe system taken along line7-7 of FIG. 6.

FIG. 8 is a top perspective view of a band saw including a removableshoe system according to another embodiment of the invention.

FIG. 9 is a cross section of the removable shoe system taken along line9-9 of FIG. 8.

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein are for the purpose ofdescription and should not be regarded as limiting.

DETAILED DESCRIPTION

FIGS. 1-7 illustrate a band saw 10 and an adjustable shoe system 91embodying some aspects of the invention. An AC version of the band saw10 having an electrical connection cord 12 is illustrated; however, infurther embodiments, DC versions of the band saw 10 including arechargeable, removable battery pack are possible.

The band saw 10 includes a housing or frame 14 supporting a motor 18 anda gear box 22. The motor 18 is drivingly connected to a drive mechanism(not shown) at least partially housed within the gear box 22. The motor18 and the drive mechanism are operable to drive a continuous band sawblade 26 to cut a workpiece. As described herein, the band saw 10includes a front 30 and a rear 34. The front 30 is defined as the sidebeing proximate the portion of the band saw blade 26 that cuts theworkpiece and the rear 34 is defined as the side proximate the portionof the band saw blade 26 that does not cut the workpiece. The rear 34 isotherwise described as being opposite the front 30.

The housing 14 includes a main handle 38 supporting a switch assembly 42to provide power to the band saw 10. The switch assembly 42 is operableto control operation of the motor 18. The band saw 10 also includes anauxiliary handle 46 for a user's other hand spaced from the main handle38. Generally, the handles 38, 46 are shaped and arranged for two-handedoperation of the band saw 10 as the workpiece is cut. In the illustratedconstruction, each handle 38, 46 has an ergonomic design to providecomfortable gripping and controlled operation of the band saw. Theergonomic design of each handle and of the combination of the handlesmay include the orientation or angle of handle(s). The ergonomic designmay also include the use of material, such as an elastomeric material,on the handle(s) to, one or more of, provide an improved grip surface,isolate vibration and impacts from the operator, prevent heat build-upand/or transfer to the operator, etc.

The housing 14 defines a first portion 50 and a second portion 54. Thefirst portion 50 and the second portion 54 are spaced apart from oneanother and define a U-shaped cavity 66 defining a cut zone 58therebetween. A blade guard 62 (FIG. 2A) is positioned at the rear 34 ofthe band saw 10 and extends between the first and second portions 50, 54within the cut zone 58. The blade guard 62 provides a recessed area tohouse the band saw blade 26.

As shown in FIG. 2A, the drive mechanism generally includes a drivewheel pulley 70 and a driven wheel pulley 74. The drive wheel 70 rotatesabout a drive wheel axis 78 defined by a drive wheel axle 79 and isdrivingly connected to the motor 18 via a drive train (not shown). Thedriven wheel 74 rotates about a driven wheel axis 82 defined by a drivenwheel axle 83 and is rotatably supported by the housing 14. The drivewheel 70 is positioned in the first portion 50 of the housing 14, andthe driven wheel 74 is positioned in the second portion 54 of thehousing 14. A wheel tire 86 is coupled to each of the peripheries of thedrive wheel 70 and the driven wheel 74. Each wheel tire 86 is acircular-shaped ring formed of a soft and/or flexible elastomericmaterial that is able to lock or adhere to the respective wheel 70, 74.The band saw blade 26 extends around the drive wheel 70 and the drivenwheel 74 and grips the blade tires 86 and, as a result, motion from thedrive wheel 70 is transmitted to the band saw blade 26 via the bladetires 86. The band saw 10 also includes a blade tensioning mechanism 90to adjustably provide appropriate tension on the band saw blade 26.

A first guide roller set 110 and a second guide roller set 114 aredisposed on each side of the cavity 66 and engage opposing sides of thesaw blade 26. The first and second guide roller sets 110, 114 supportthe band saw blade 26 as the blade 26 enters and exits the cut zone 58.

The band saw 10 also includes an adjustable shoe system 91 including ashoe 92 for positioning against the workpiece, a connector block 96 forcoupling the shoe 92 to the housing 14, and a detent mechanism 161(FIGS. 5A and 5B) for holding the shoe 92 in select positions relativeto the connector block 96. The shoe 92 is coupled to the housing 14 byway of the connector block 96 and the detent mechanism 161.

With reference to FIGS. 2A-7, the connector block 96 is a generallyT-shaped member coupled to the housing 14 by fasteners 138. Theconnector block 96 is coupled to the first portion 50 of the housing 14adjacent the drive wheel 70 and is positioned in or adjacent the cavity66 at an end of the cut zone 58. The connector block 96 includesfastener apertures 142 through which the fasteners 138 are disposed tocouple the connector block 96 to the housing 14. In the illustratedconstruction, two fastener apertures 142 (FIG. 5A) and two screws 138(FIG. 5B) are employed. In other constructions, fewer or more fastenersand fastener apertures may be employed to couple the connector block 96to the housing 14, or the connector block 96 may be integrally formedwith the housing 14.

The connector block 96 includes a main body portion 146 and first andsecond extending portions or flanges 150, 154 generally forming aT-shape, as shown in FIG. 7. In the illustrated embodiment, the mainbody portion 146 is positioned adjacent the housing 14 and engages thehousing 14 when the connector block 96 is fastened to the housing 14.The main body portion 146 includes first and second pins 170, 174extending therefrom for locating the connector block 96 with respect tothe housing 14. As illustrated in FIG. 5B, the pins 170, 174 arereceived by apertures or recesses in the housing 14. The first andsecond extending portions 150, 154 communicate with the shoe 92, asdescribed below.

The connector block 96 also includes a recess or aperture 158 forreceiving the detent mechanism 161 (FIGS. 5A and 5B). The detentmechanism 161 includes a ball detent 162 and a biasing member 166, suchas a leaf spring. The ball detent 162 is biased by the biasing member166 to an extended position away from the housing 14 for engaging theshoe 92 and holding the shoe 92 in position with respect to the housing14. In other constructions, the biasing member 166 may include othertypes of springs and biasing members, such as a coil spring.

With further reference to FIGS. 3-7, the shoe 92 includes a generallyC-shaped body member 172 and a workpiece-engaging member 176. The bodymember 172 wraps around and slideably engages the first and secondextending portions 150, 154 of the connector block 96. An axis 98 of theadjustable shoe system 91 is defined by the direction the shoe 92 slidesrelative to the connector block 96. The axis 98 is also defined by anaxis of symmetry of the body member 172. In the illustrated embodiment,the detent mechanism aperture 158 and the fastener apertures 184 arecentered on the axis 98. The workpiece-engaging member 176 generallyextends along the axis 98 below the cut zone 58 and away from thehousing 14 of the band saw 10. The shoe 92, and in particular theworkpiece-engaging member 176, engages a workpiece (not shown) in orderto secure the workpiece relative to the band saw blade 26 within the cutzone 58 during a cutting operation. The workpiece-engaging member 176includes a groove or slot 180 in which the band saw blade 26 ispositioned, as shown in FIGS. 2A-2B. The direction of movement of theband saw blade 26 through the slot 180 is generally perpendicular to theaxis 98, and a plane of the band saw blade 26 extending through the slot180 is generally parallel to the axis 98.

Referring to FIGS. 2A-6, the shoe 92 includes apertures 184 forreceiving the detent mechanism 161 and holding or locating the shoe 92in position relative to the housing 14. The ball detent 162 is biasedtoward the shoe 92 and is received by one of the apertures 184 to engagethe shoe 92 and hold the shoe 92 in a position corresponding to therespective aperture 184. In the construction of FIGS. 2A-7, the shoe 92includes two apertures 184 and is adjustable between a first engagedposition and a second engaged position. In the first position, the balldetent 162 is received by a first of the apertures 184 and engages theshoe 92 to hold the shoe 92 in the first position (FIGS. 2A, 2B, and5A-6), i.e., to hold the shoe 92 with respect to the connector block 96.In the second position, the ball detent 162 is received by a second ofthe apertures 184 and engages the shoe 92 to hold the shoe 92 in thesecond position.

The first position is an extended position, extending away from thehousing 14, for accommodating larger workpieces. The second position isa recessed position, recessed toward the housing 14, for accommodatingsmaller workpieces or cutting flush against a surface, such as a ceilingor wall. In the fully recessed position, the end of the shoe is adjacentor near a bottom edge (i.e., the cutting edge) of the band saw blade 26.A non-engaged position includes a position in between the first andsecond positions. In the non-engaged position, the ball detent 162 isnot received by the apertures 184. The non-engaged position may alsoinclude a position in which the shoe 92 is removed from the connectorblock 96. In other constructions, three or more apertures 184 may beemployed such that the shoe 92 is adjustable between three or morepositions ranging from a fully extended to a fully recessed andintermediate positions therebetween for positioning and securing theband saw 10 with respect to a variety of workpieces of varying sizes andshapes.

FIGS. 8-9 illustrate a removable shoe system 178, given the samereference numerals as the adjustable shoe system 91 shown in FIGS. 1-7.The removable shoe system 178 is similar to the adjustable shoe system91 except that the shoe 92 includes only one aperture 184. In thisconstruction, the shoe 92 is moveable between an engaged position inwhich the ball detent 162 is received by the aperture 184 and anon-engaged position in which the shoe 92 is removed from the connectorblock 96. The non-engaged position may also include an intermediateposition in which the shoe 92 is not removed, but in which the balldetent 162 does not engage the aperture 184.

In order to adjust the position of the shoe 92, a user applies a forceon the shoe 92 in the direction of the axis 98. The force causes thebody of the shoe 92 to engage the ball detent 162 and overcome thebiasing force of the biasing member 166. The ball detent 162 is movedtoward the housing 14 and engages an inner surface of the shoe 92 as theshoe 92 is moved to another position or removed. When one of theapertures 184 is positioned adjacent the ball detent 162, the balldetent 162 is pushed at least partially into the one of the apertures184 by the biasing spring force and engages the body of the shoe 92surrounding the one of the apertures 184 to hold the shoe 92 in place.In operation, the shoe 92 is adjusted by applying a force on the shoe 92in either direction along the axis 98 to move the shoe 92 to a desiredposition depending on the size and shape of the workpiece being cut, orto remove the shoe 92. No tools or removal of fasteners are required toadjust or remove the shoe 92.

Although particular constructions embodying independent aspects of thepresent invention have been shown and described, other alternativeconstructions will become apparent to those skilled in the art and arewithin the intended scope of the independent aspects of the presentinvention.

What is claimed is:
 1. A band saw comprising: a first wheel and a secondwheel for supporting a continuous band saw blade; a motor operable todrive at least one of the first and second wheels; a housing supportingthe first wheel and the second wheel; a shoe for engaging a workpiece,the shoe including a first detent feature; and a second detent featurecooperating with the first detent feature to hold the shoe with respectto the housing; wherein the shoe is moveable in a direction with respectto the housing between an engaged position in which the first and seconddetent features cooperate to hold the shoe with respect to the housing,and a non-engaged position in which the shoe is movable; wherein theshoe is moveable out of the engaged position by application of a forceacting on the shoe and acting substantially in the direction to move theshoe with respect to the housing, and acting to overcome cooperationbetween the first and second detent features in the engaged position. 2.The band saw of claim 1, wherein the shoe is moveable out of the engagedposition by application of the force directly on the shoe sufficient toovercome cooperation between the first and second detent features in theengaged position and cause the shoe to move relative to the housing. 3.The band saw of claim 1, wherein at least one of the detent featuresincludes a biasing member providing a biasing force acting to hold theshoe with respect to the housing in the engaged position, whereinapplication of the force on the shoe acts to compress the biasing memberand cause the shoe to move relative to the housing when the force issufficient to overcome the biasing force.
 4. The band saw of claim 1,further comprising first and second outwardly extending flanges, whereinthe shoe includes a generally C-shaped member wrapped around andslideably engaging the first and second flanges.
 5. The band saw ofclaim 4, wherein the first and second outwardly extending flanges extendfrom a main portion such that the first and second outwardly extendingflanges and the main portion together form a generally T-shaped crosssection received by the generally C-shaped member.
 6. The band saw ofclaim 1, wherein the second detent feature includes a biasing member anda ball biased in a first direction by the biasing member, and the firstdetent feature includes a first aperture in the shoe for receiving theball to hold the shoe with respect to the housing in the engagedposition.
 7. The band saw of claim 6, wherein the engaged position is afirst engaged position, and wherein the shoe further includes a secondaperture for receiving the ball to hold the shoe with respect to thehousing in a second engaged position.
 8. The band saw of claim 6,wherein the biasing member includes a leaf spring.
 9. The band saw ofclaim 6, wherein the biasing member biases the ball toward the shoe. 10.The band saw of claim 1, wherein the non-engaged position includes aremoved position in which the shoe is disengaged from the housing suchthat the shoe is removable.
 11. The band saw of claim 1, wherein theshoe is moveable between a plurality of engaged positions.
 12. The bandsaw of claim 1, wherein at least one of the detent features includes abiasing member that compresses as the shoe moves from the engagedposition to the non-engaged position.
 13. A band saw comprising: ahousing supporting a motor operable to drive a continuous band saw bladeto cut a workpiece, the housing having a first portion and a secondportion; a cavity between the first portion and the second portion forreceiving the continuous band saw blade and accommodating a workpieceduring a cutting operation; and a shoe assembly coupled adjacent thecavity to the first portion of the housing, the shoe assemblycomprising, a first detent feature, a body having a surface for engaginga workpiece, and a second detent feature for cooperating with the firstdetent feature to hold the body with respect to the housing, wherein thebody is moveable in a direction with respect to the housing between anengaged position in which the first and second detent features cooperateto hold the body with respect to the housing, and a non-engaged positionin which the body is movable; wherein the body is moveable out of theengaged position by application of a force acting on the body and actingsubstantially in the direction to move the body with respect to thehousing, and acting to overcome cooperation between the first and seconddetent features in the engaged position.
 14. The band saw of claim 13,wherein at least one of the detent features includes a biasing memberconfigured to compress as the shoe moves from the engaged position tothe non-engaged position.
 15. The band saw of claim 13, wherein the bodyis moveable out of the engaged position by application of the forcedirectly on the body of a magnitude_sufficient to overcome cooperationbetween the first and second detent features in the engaged position andcause the body to move relative to the housing.
 16. The band saw ofclaim 13, wherein at least one of the detent features includes a biasingmember providing a biasing force acting to hold the body with respect tothe housing in the engaged position, wherein application of the force onthe body acts to move the at least one of the detent features in adirection away from the body and cause the body to move relative to thehousing when the force is of a magnitude sufficient to overcome thebiasing force.
 17. The band saw of claim 13, wherein first and secondoutwardly extending flanges extend from the housing, and wherein thebody includes a generally C-shaped member wrapped around and slideablyengaging the first and second flanges.
 18. The band saw of claim 17,wherein the first and second outwardly extending flanges extend from amain portion such that the first and second outwardly extending flangesand the main portion together form a generally T-shaped cross sectionreceived by the generally C-shaped member.